Method of shaping chocolate products

ABSTRACT

Methods of producing shaped, embossed, or decorated confectionery chocolate products by using chilled forming, shaping, or embossing devices.

This application is a continuation of U.S. application Ser. No.08/782,901 filed Jan. 11, 1997 now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to methods of forming shaped or embossedchocolate compositions that can include detailed designs and/or planarsurfaces.

2. Related Background Art

The unique flavor and mouthfeel of chocolate is a result of thecombination of numerous components as well as the process ofmanufacture. Chocolate contains solid particles dispersed throughout afat matrix (the term “fat” includes cocoa butter and milk fat).

Similarly, chocolate-like compositions may also contain fats other thancocoa butter or milk fat. Accordingly, melted chocolate andchocolate-like compositions are suspensions of non-fat particles (e.g.,sugar, milk powders and cocoa solids) in a continuous liquid fat phase.The fat phase of milk chocolate, for example, is typically a mixture ofcocoa butter, a suitable emulsifier, and milk fat. Cocoa butter istypically the predominant fat in the chocolates.

Cocoa butter is a polymorphic material in that it has the ability tocrystallize in a number of different crystal packing configurations(Wille and Lutton “Polymorphism of Cocoa Butter”, J. Amer. Oil Chem.Society, Vol. 43 (1966) pages 491-96, herein incorporated by referencein its entirety). Six different polymorphic forms are generallyrecognized for cocoa butter. Forms I and II are produced, for example,by rapidly cooling melted untempered chocolate to low temperatures andare very unstable with low melting points. Forms III and IV melt athigher temperatures than Forms I and II but are not the most desirousforms for confectionery manufacture. Forms V and VI are the most stableforms of cocoa butter. It is desirable to have Form V as the predominantform in a well-tempered chocolate. Form V transforms slowly into Form VIafter a period of time. Accordingly, chocolate processing is stronglylinked to the crystallization and polymorphic behavior of the fat phase.Before chocolate can be satisfactorily processed from liquid to solidusing conventional methods, it must be tempered after which it is gentlycooled to form a set chocolate having a stable fat phase.

The most commonly used method of processing chocolate involves thefollowing sequential steps:

A. complete melting of the chocolate fat phase;

B. cooling to the point of initial crystallization of the fat phase(i.e., below the melting point of the liquid fat phase);

C. crystallizing a portion of the liquid fat phase;

D. slight heating to melt out any unstable crystals that may have formedleaving from about 3 to 8 wt % as seeds for crystallizing the remainingliquid fat; and

E. gently cooling to set the chocolate, typically in a cooling tunnel.

During conventional chocolate processing, the chocolate mixture isinitially melted at temperatures of about 45° C. and tempered by coolingwith agitation to about 29° to 30° C. The tempering of the chocolateresults in a chocolate dispersion having fat crystals dispersedthroughout the liquid fat phase. The chocolate suspension may then befurther processed prior to setting by, for example, enrobing thechocolate onto an edible center or molding the chocolate. The chocolateis finally set into a form sufficiently solid for wrapping by gentle,controlled cooling.

Conventional tempering is the controlled partial precrystallization ofthe fat phase which is believed to be necessary to produce a stablesolid form of the fat in the finished product. Therefore, one importantobject of tempering is to develop a sufficient number of stable seedcrystals so that under appropriate cooling conditions the fat phase ofthe chocolate is able to crystallize into a stable polymorphic form.Tempering plays a key role in ensuring that the cocoa buttercrystallizes in the stable form. “Chocolate must be properly tempered.Undertempered chocolate causes delayed setting in the cooler andadhesion to [processing equipment such as a] conveyor belt, andultimately bad chocolate color and fat bloom” (see Chocolate, Cocoa andConfectionery: Science and Technology, by Minifie, 3rd Ed., p. 218,herein incorporated by reference in its entirety).

Although it is important that the chocolate is well seeded with stableforms of cocoa butter crystals, the tempered chocolate still contains ahigh proportion of liquid cocoa butter, estimated from about 92 to 97 wt% of the fat phase. This must be solidified or at least partiallysolidified in the cooling process so that the set chocolate can bewrapped and ultimately be completely solidified into a stablecrystalline form. (see Chocolate, Cocoa and Confectionery: Science andTechnology, by Minifie, 3rd Ed., p. 195, herein incorporated byreference in its entirety).

Chocolates having a desired three-dimensional shape or having an imageor design imprinted on a surface (herein referred to as “formedchocolates”) are conventionally produced by molding. Molding is thecasting of liquid chocolate into molds (plastic or metal) followed bycooling and demolding. The finished chocolate may be a solid block, ahollow shell, or a shell filled with a confectionery material such asfondant, fudge or soft caramel (Chocolate. Cocoa and Confectionery:Science and Technology by Bernard W. Minifie, Third Edition, page 183,herein incorporated by reference in its entirety).

The term molding includes methods wherein chocolate is deposited intomolds, allowed to cool and hardened into solid pieces. The chocolatesused in molding processes usually can be somewhat more viscous thancoating chocolates since the chocolate can be vibrated and/or forcedinto a mold over a longer period of time than allowed in enrobing, forexample. However, chocolate molded with food inclusions generally mustbe as fluid as coating chocolates.

Formed chocolate products are conventionally produced by depositingtempered chocolate having a liquid fat phase into molds, allowing thechocolate to cool and harden into solid pieces before demolding thechocolate (Chocolate. Cocoa and Confectionery: Science and Technology byBernard W. Minifie, Third Edition, pages 198-206, herein incorporated byreference in its entirety).

The most commonly used method of producing a shaped chocolate involvesthe following sequential steps:

A. heating the chocolate to soften, i.e., melting of the fat phase;

B. tempering the chocolate;

C. depositing the tempered chocolate into a mold;

D. shaking the mold to remove air bubbles and fully distribute thechocolate in the mold cavity;

E. cooling to harden the chocolate; and

F. removing said set shaped chocolate from said mold (“de-molding”).

One disadvantage of the conventional molding process is the excessivetime required to fill the mold, shake the mold to remove air pockets andsolidify the chocolate to form a shaped piece. The molding timetypically exceeds 10 to 20 minutes. The requirement of the use of moldsto form shaped or decorated products greatly reduces the efficiencies ofsuch commercial production lines.

The decoration or embossing of a surface of a chocolate, typically thetop surface, by conventional methods is also disadvantageous. In thehand-dipping days, decorations were made by hand using hand tools(Industrial Chocolate Manufacture and Use by S. T. Beckett, secondedition, page 227, herein incorporated by reference in its entirety).The Sollich Decormatic [Sollich GMBH &Co., KG, Bad Salzuflen, Germany]and Woody Stringer [Woody Associates, Inc., York, Pa., USA] are twoconventional decorating apparatuses. The Decormatic decorates thechocolate by applying additional chocolate through a nozzle. Thedecoration is limited by the movement of the nozzles in relation to thechocolate product (i.e., circulatory or oscillating movements). TheWoody Stringer also functions by applying additional chocolate onto thechocolate product to form a decoration. Such devices are limited to thespeed in which the additional decorative chocolate can be applied.Moreover, the types of decorations that can be created are limited tothose which are able to be formed with the chocolate applicator. Thesetypes of devices cannot be used to form the chocolate product into aparticular shape or provide a chocolate having an image embossed on atleast one surface.

There are a variety of methods in the prior art to decorate chocolatesurfaces. U.S. Pat. No. 4,946,696 to Nendl et al. relates to thecreation of fine patterns in chocolate surfaces using offset printing ofa colored cocoa butter pattern on a printing sheet and thereafterembedding it in a molded chocolate surface. U.S. Pat. No. 4,668,521 toNewsteder relates to a process for producing a photographic qualitylikeness of a photographic image on the surface of a chocolate candy.The method involves the use of a film surface of a photorelief imaged ina photosensitive element such that peaks and valleys are created in thephotosensitive element corresponding to the selected image. A deformabletransfer blanket is cast against the photosensitive element surface torecord in a surface of the transfer blanket peaks and valleyscorresponding to the selected image. A chocolate material is then castagainst the surface of the transfer blanket to record the selected imageby peaks and valleys in the surface of the chocolate. U.S. Pat. No.4,455,320 to Syrmis relates to a method for sculpting a person's facefrom a photograph onto a chocolate candy by adapting a photographicimage of a person's face, converting the adapted image into a transfermedium or die and then embossing such adapted image onto chocolatecandy. U.S. Pat. No. 4,183,968 to Beckers relates to a method andapparatus for continuously stamping pieces of candy from travellinglengths of confectionery material and comprises rotating laterally openchambers into which is arranged to project, from opposite sides thereof,axially disposed co-rotating stamping dies. U.S. Pat. No. 3,303,796 toNovissimo relates to a method for continuously forming three-dimensionalconfectionery shapes in sheet form by a roll-pressing operation. U.S.Pat. No. 2,304,494 to Cahoon relates to candy-forming machines forcontinuously molding confectionery products. U.S. Pat. No. 1,522,738 toMiller relates to the production of candy in the form of strips whichare substantially rectangular in cross-section. The above U.S. patentsare herein incorporated by reference in their entirety.

U.S. Pat. No. 4,648,829 to Cattani relates to a device for shaping icecreams and food articles that have a thick and creamy nature comprisingat least one forming unit including an air-pervious contoured die anddrive elements for moving the die, and members operative to supplycompressed air to the die from the opposite side thereof to thatengagable to articles to be shaped. U.S. Pat. No. 4,847,090 to DellaPosta et al. relates to improved confectionery products which arecharacterized in having a single product body of discrete componentparts at least certain of which differ from others in respect to theirphysical and/or chemical properties. A co-extruded confection productmay be shaped via the use of opposed forming dies. The above U.S.patents are herein incorporated by reference in their entirety.

The above-identified methods of forming shaped chocolate products orchocolate products having an embossed surface are slow and lackefficiency. When compared to other processing steps in making achocolate, the molding process is inefficient. While a conventionalenrobing line, for example, can operate at up to 10,000 pieces/minute,molding lines can only operate at about 2,000 pieces/minute for moldingpieces of similar widths, sizes and shapes. Molding produces, however,desirable properties such as high gloss and detail not attainable byother methods. Such inabilities of other processes to provide anacceptable gloss and the high detail comparable to that provided by amolded product, without the use of a mold, reduces the commercialefficiencies of conventional chocolate processing facilities. It wouldbe desirable to provide a method of making such products in a moreefficient manner.

Some known methods have incorporated the use of chilled molds or chilledplunging devices to set chocolate products more rapidly. However, theknown methods utilizing molds still require the time consuming steps of(i) shaking the mold to remove air bubbles and to distribute thechocolate in the mold, as well as (ii) setting the chocolate in the moldto allow for de-molding. Moreover, the use of chilled molds by priormethods results in chocolate products having poor gloss. The followingreferences relate to methods of using chilled molds or molds withchilled plungers.

PCT Patent Publication WO 95/32633 to Aasted relates to a method forproducing molded shells of fat-containing, chocolate-like masses whereina mold cavity is filled with a mass and a cooling member having atemperature below 0° C. is subsequently immersed in the mass to define apredetermined shell volume between the member and the mold cavity. Thispublication is incorporated by reference herein in its entirety.

U.K. Patent publication GB 2 070 501 relates to making confections, suchas chocolates and the like, of substantially uniform size. The methodinvolves the steps of depositing a gob of flowable confectionerysubstance onto a surface, surrounding the gob in spaced relationshipwith an annular mold, exerting pressure upon the gob to cause the gob tospread apart and come into contact with the mold causing the gob to setso as to form a confectionery body in the mold and separating theconfectionery body and the molds from one another. Pressure is exertedon the gob by a ram. It is advantageous if each of the annular molds hasa hollow circumferential wall and if a cooling fluid circulates throughthis hollow wall to create a cooling channel so as to obtain a rapidchilling (and thus setting) of the gob. The inner circumference of themold may have any desired regular or irregular shape, depending uponwhat shape is desired to impose upon the finished confectionery body.This publication is incorporated by reference herein in its entirety.

European Patent Application 0 589 820 to Aasted relates to a method forproducing molded outer shells of fat-containing, chocolate-like masseswherein a mold cavity is filled with a tempered chocolate-like masswhich solidifies from the mold cavity inwardly to form the outer shapeof the shell, the temperature of the mold cavity being lower than thetemperature of the tempered mass. The mold cavity is filled with achocolate-like mass in an amount which is just slightly larger than thevolume of the finished shell. A cooling member, which has preferablybeen cooled to −15 to −30° C., is then immersed into the chocolate massand kept in a fully immersed position for about 2 to 3 seconds. Thechocolate-like mass will then solidify rapidly during crystallizationfrom the cooling member and will readily release the cooling member,which can be lifted up and out of the mold of the cavity. Thispublication is incorporated by reference herein in its entirety.

PCT Patent Publication WO 94/07375 to Cebula et al. relates to formingfat-containing products such as chocolate in molds at temperatures at orbelow 0° C. to provide unforced demolding. This publication isincorporated by reference herein in its entirety.

U.S. Pat. No. 4,426,402 to Kaupert relates to a method and an apparatusfor producing chocolate forms using molding tools. During an injectionstep, the molding tool is cooled with a coolant, wherein one of themolding parts is maintained at about 20° C., while the other ismaintained at a substantially lower temperature of 0° C. or less, suchas about −5° C. Even lower temperatures, such as −10° C. and even −20°C., are disclosed as acceptable for still faster molding speeds if theformed chocolate body is carefully handled. This U.S. patent isincorporated by reference herein in its entirety.

The above-identified references fail to teach or suggest forming,shaping, or embossing methods to produce embossed or highly detailed andhighly reproducible decorated chocolates having acceptable gloss withthe efficiency and speed of an enrobing line. Thus, the development ofmethods which increase the speed and efficiencies of shaped chocolateprocessing lines would be a valuable addition to the art and offeralternate manufacturing methods.

The above-identified references also fail to teach or suggest that it ispossible to emboss highly intricate details onto the tops of enrobedproducts. A method to add reproducible fine details to an enrobingprocess is not currently available. Thus, the development of methodswhich enable the convenient inclusion of highly intricate designs on thesurfaces of enrobed products would be a valuable addition to the art andoffer expanded opportunities for manufacture and design.

SUMMARY OF THE INVENTION

The invention relates to a method of producing shaped, formed, embossed,or decorated confectionery chocolate products using a chilled forming,shaping, or embossing device. According to one aspect of the invention,a chocolate composition is deposited onto a surface and the chilleddevice is brought into contact with a surface of the chocolatecomposition to at least partially solidify the contacted surface.According to one embodiment, a chilled former/shaper or embosser isbrought down and contacted with a chocolate composition containing aliquid fat phase to solidify the contacted chocolate mass into a formsufficiently solid to retain the desired shape/form and/or with thedesired image or design embossed on the contacted surface. The chocolatemay be first deposited onto a surface (i.e., conveyor belt) or enrobedonto an edible center and subsequently contacted with the chilledforming/shaping or embossing device to form the formed/shaped orembossed chocolate product.

According to another embodiment, the chocolate is first enrobed onto anedible product and a surface of the enrobed edible product is contactedwith a chilled embossing device to form an image or design on thecontacted surface and subsequently set in a cooling chamber. Otherenrobed edible products such as caramel, nougat, etc. may also beproduced. Moreover, multi-component food products may be formed. Forexample, two different materials may be co-extruded or co-deposited ontoa deposition surface with one component (i.e., chocolate) surroundingthe second component and subsequently shaped/formed or embossed with thechilled device to form a shaped product having an inner component and anouter component.

Another aspect of the invention relates to the ability to provide anacceptably glossy chocolate product using a chilled forming/shaping orembossing device. One embodiment relates to controlling the contactingtime of the chilled device with the chocolate surface to allow the innerwarmer portions of the chocolate mass to assure that fat is adequatelyexpressed across the surface, contributing to the preparation ofproducts with acceptable gloss.

Factors that affect the gloss of the chocolate mass are (i) the contacttime with the forming/shaping or embossing device, (ii) the temperatureof the forming/shaping or embossing device, and (iii) the rewarmingprocess caused by internal and external heat. The above factors affectthe surface temperature thereby affecting the fat expression on thesurface and consequently, the preparation of a product with acceptablegloss.

Accordingly, another embodiment relates to the use of a subsequentwarming zone after the chilled contracting step to allow fat to expresson the surface. Yet another embodiment relates to the use of a formingcavity coated with material which improves the wetting properties of thechocolate, thereby affecting its gloss. A still further embodimentinvolves the heating of the cavity to improve wetting properties toaffect the gloss. A still further embodiment relates to the use ofseeded chocolate having higher temperatures at the time of beingcontacted with the chilled device to provide better wetting of thechilled device and/or better fat expression on the surface.

Yet another aspect of the invention relates to improved methods ofmaking formed chocolates using seed agents that eliminates the dramaticincreases in viscosity typically associated with tempered chocolate. Theinvention also relates to the ability to process chocolates at highertemperatures without the need to temper at low temperatures providingeven further improved rheological properties.

The use of seeding agents to provide temper without initiating thecrystallization of the liquid fat phase that occurs during conventionaltempering provides a chocolate composition that is easier to form/shapeor emboss into a formed/shaped or embossed product. Preferably, the useof seeding agents according to the invention actually postpones thecrystallization of the fat phase. This enables the seeded chocolate tobe used in shaping/forming or embossing applications that require lowerviscosities. The use of the seeded compositions in such applicationsallows for the manufacture of high quality products such asshaped/formed or embossed products having finer details with lower fatcontents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1(a) is a top side elevational perspective view of a chocolateconfection having a detailed embossed image formed on a top surfaceaccording to one embodiment of the present invention.

FIG. 1(b) is a top side elevational perspective view of a chocolateconfection having a highly detailed improved embossed image on a topsurface made according to another embodiment of the present inventionusing a colder embosser, longer contact time and/or use of subsequentrapid cooling treatment.

FIG. 2 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 3 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 4 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 5 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 6 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 7 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 8 is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 9A is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 9B is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 9C is a schematic sectional side view of a forming method accordingto an embodiment of the present invention.

FIG. 10A is a schematic sectional side view of a forming methodaccording to an embodiment of the present invention.

FIG. 10B is a schematic sectional side view of a forming methodaccording to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Definitions

1. The term “chocolate” is intended to refer to all chocolate orchocolate-like compositions with a fat phase or fat-like composition. Asthe invention is directed to the control of the characteristics of thefat or fat-like phase of the chocolate, rather than the non-fatmaterials within the chocolate, the term is intended to include allchocolate and chocolate-like compositions. The term is intended, forexample, to include standardized and non-standardized chocolates, i.e.,including chocolates with compositions conforming to the U.S. StandardsOf Identity (SOI) and compositions not conforming to the U.S. StandardsOf Identity, respectively, including dark chocolate, baking chocolate,milk chocolate, sweet chocolate, semi-sweet chocolate, buttermilkchocolate, skim-milk chocolate, mixed dairy product chocolate, low fatchocolate, white chocolate, aerated chocolates, compound coatings,non-standardized chocolates and chocolate-like compositions, unlessspecifically identified otherwise.

The fat phase of the chocolate of the present invention can includecocoa butter, milkfat, anhydrous milkfat, butteroil, hydrogenated orpartially hydrogenated vegetable oils or fats (fractionated orunfractionated) and other fats or mixtures of cocoa butter with theseother fats. See Minifie, Chocolate, Cocoa and Confectionery Science andTechnology 3rd Ed. pages 100-109.

In the United States, chocolate is subject to a standard of identityestablished by the U.S. Food and Drug Administration (FDA) under theFederal Food, Drug and Cosmetic Act. Definitions and standards for thevarious types of chocolate are well established in the U.S.Nonstandardized chocolates are those chocolates which have compositionswhich fall outside the specified ranges of the standardized chocolates.

Chocolates also include those containing crumb solids or solids fully orpartially made by a crumb process.

Nonstandardized chocolates result when, for example, the nutritivecarbohydrate sweetener is replaced partially or completely; or when thecocoa butter or milkfat are replaced partially or completely; or whencomponents that have flavors that imitate milk, butter or chocolate areadded or other additions or deletions in formula are made outside theUSFDA standards of identify of chocolate or combinations thereof.

2. The term “chocolate confection” refers to chocolate products that arestable at ambient temperatures for extended periods of time (i.e.,greater than 1 week). These products are characterized asmicrobiologically shelf-stable at 65°-85° F. under normal atmosphericconditions. The term “confection” is not intended to include ice creamproducts or other products that are typically stored at temperaturesbelow 0° C. and which are designed to be consumed while in a frozenstate. As a confection, chocolate can take the form of solid pieces ofchocolate, such as bars or novelty shapes, and can also be incorporatedas a component of other, more complex confections where chocolate iscombined with and generally coats other foods such as caramel, nougat,fruit pieces, nuts, wafers or the like. Other complex confections resultfrom surrounding soft inclusions such as cordial cherries or peanutbutter with chocolate and other complex confections result from coatingice cream or other frozen or refrigerated desserts with chocolate.However, chocolate coatings on ice cream or other frozen productstypically do not contain stable fat crystals and are not included in thepresent invention.

3. The term “chocolate-like compositions” refers to chocolate flavoredcompositions containing solid particles dispersed in a fat or fat-likephase.

4. The term “cooled chocolate” refers to a melted chocolate which hasbeen cooled to produce a solid chocolate wherein substantially all ofthe fat is in a solid state.

5. The term “crystalline fat” refers to a liquid fat which has beencooled to allow the fat to undergo a phase transition to one or morecrystalline forms or polymorphs. For example, cocoa butter maycrystallize as any one of six recognized polymorphs.

6. The term “set chocolate product” refers to a product in whichsufficient fat has solidified at a given temperature to provide theproduct with a minimum degree of physical integrity, such that its shapeand appearance are maintained at the given temperature.

7. The term “fats”, as used herein, refers to triglycerides,diglycerides and monoglycerides that can normally be used in chocolatesand chocolate-like products. Fats include the naturally occurring fatsand oils such as cocoa butter, pressed cocoa butter, expeller cocoabutter, solvent extracted cocoa butter, refined cocoa butter, milkfat,anhydrous milkfat, fractionated milkfat, milkfat replacers, butterfat,fractionated butterfat, hydrogenated or partially hydrogenated vegetablefats or oils (fractionated or unfractionated), modified vegetable fatsand synthetically modified fats such as Caprenin®.

8. The term “chocolate setting temperature” refers to the temperature towhich a chocolate composition must be cooled to produce a “set chocolateproduct”.

9. The term “chocolate melt temperature” refers to the temperature of achocolate composition comprising a liquid fat phase. This temperaturecan range from the “chocolate setting temperature” up to any highertemperatures typically encountered in chocolate processing. Conversely,“chocolate melting temperature” would refer to the temperature at whichpoint the fat phase is completely melted.

10. The term “chocolate composition comprising a liquid fat phase”refers to a chocolate or chocolate-like composition where the fat phaseis liquid or partially liquid.

11. The term “force sufficient to cause flow” refers to the force ormore properly the stress which must be applied to a chocolate comprisinga liquid fat phase to cause it to flow at a finite shear rate. Theapplied stress must be sufficient to overcome the yield stress of thechocolate. Such force may be applied during a number of differentchocolate processing operations such as spraying, atomization, injectionmolding, pouring, enrobing, extrusion, shaping, spin molding, pumping,dripping, depositing, molding or combinations thereof.

12. The term “continuous fat phase” refers to the fat phase of achocolate which represents the continuous phase into which are dispersedthe non-fat particles, added seeding agent particles and anyconventionally produced fat seed crystals, where the chocolate in afluid state is representative of a solid in liquid dispersion.

13. The term “fat bloom” refers to the uncontrolled recrystallization offat on the surface of a chocolate product characterized as a grayishcoating on the surface of the chocolate.

14. The term “processing temperature range” refers to the temperaturerange between the chocolate solidification temperature and the seedmelting temperature.

15. The term “seeded chocolate” refers to a chocolate comprising aliquid fat phase to which a seeding agent has been added.

16. The term “stable fat crystals” refers to those crystalline forms orpolymorphs that are stable at higher temperatures; that is, thesepolymorphs have higher melting points. For cocoa butter, six crystalpolymorphs have been recognized and characterized by both thermalanalysis and X-ray diffraction. These six forms are well known to thoseskilled in the art of chocolate manufacture (see Wille et al.“Polymorphism of Cocoa Butter”, J. Am. Oil Chem. Soc., Vol. 43 (1966)pages 491-96). Referring to cocoa butter then, the term “stable fatcrystals” is meant to include the form V and form VI polymorphs whichmelt at higher temperatures. The term “unstable fat crystals” refers tothe remaining lower melting lower polymorphs.

17. The term “temper” refers to the presence of stable fat crystals in achocolate. The degree or level of temper in a chocolate can be measuredby commercially available instruments which characterize the behavior ofa chocolate sample during controlled cooling. An example of this type ofinstrument is the Tricor Tempermeter [Tricor Instruments, Elgin, Ill.]which in its standard embodiment, determines chocolate temper during a 5minute controlled cooling test. Specifically, the Tricor Tempermeterdetects and measures an inflection point in a temperature versus timecurve or trace. The units of temper, using the Tricor Tempermeter, maybe expressed as chocolate temper units (CTU) and/or as a slopemeasurement. CTU measurements can be expressed in either Fahrenheit orCelsius temperature scale terms. All CTU measurements herein referred toherein are in the Fahrenheit scale, unless otherwise specified.Fahrenheit CTU measurements can be converted to Celsius scale bydividing by a factor of 1.8. Higher CTU values and lower slope valuescorrespond with higher levels of temper. If there is no detectableinflection in the 5 minute trace, the chocolate would typically beassessed as having no temper.

18. The term “low temper” refers to temper which cannot be detectedi.e., no inflection, with a Tricor Tempermeter during a 5 minute trace,but which can be measured with a Tricor Tempermeter which has beenmodified to perform a 9.5 minute trace. The units of measurement are thesame as used for the measure of “temper”. If there is no detectableinflection in the 9.5 minute trace, i.e., the longest test timecurrently available with a Tricor unit, the chocolate would then bedescribed as having no temper. However, it is nonetheless possible forsuch chocolates to have temper.

To measure temper levels below this limit, a method was developed usinga rotational rheometer, in this case a Carri-Med Controlled StressRheometer Model CSL 500. By performing controlled cooling and shearingtests it is possible to compare the onset temperature of crystallizationfor chocolate with no inflection in a 9.5 minute trace to the onsettemperature for the same chocolate which has been heated prior toanalysis to ensure a true no temper condition. This difference in onsettemperature is defined as a Rheological Temper Unit (RTU). The range oftemper between truly no temper chocolate and the lowest level measurablein a 9.5 Tricolor Tempermeter minute trace with a Tricor Tempermeter isdefined as ultra-low temper. A more detailed description of thetechnique is given below.

19. Ultra-low temper

The term “ultra-low temper” refers to temper which cannot be detected,i.e., no inflection, with a Tricor Tempermeter during a 9.5 minutetrace, but which can be measured using a more sensitive rheologicalmeasuring technique as discussed further below. Ultra-low temper isexpressed in rheological temper units (RTU). The term is described inmore detail in U.S. Pat. application Ser. No. 08/782,903, filed Jan. 11,1997 and herein incorporated by reference.

20. The term “molding” refers to methods wherein chocolate, either plainor mixed with additives such as nuts, raisins, crisped rice and the likeis deposited in molds, allowed to cool and hardened into solid pieces.The chocolates used in molding processes usually can be somewhat moreviscous than coating chocolates since the chocolate can be vibratedand/or forced into a mold over a longer period of time than allowed inenrobing, for example. However, chocolate molded with food inclusionsand/or chocolate used for shell molding generally must be as fluid andsometimes even more fluid as coating chocolates.

21. “Reduced calorie fat”, as used herein, is a fat having all theproperties of typical fat but exhibiting less calories than typical fat.An example of a reduced calorie fat is Caprocaprylobehenin, commonlyknown as Caprenin® [Proctor and Gamble, Inc., Cincinnati, Ohio], asdescribed in U.S. Pat. No. 4,888,196 to Ehrman, et al., which isincorporated herein by reference.

22. The term “gloss” refers to a physical property which ischaracteristic of the visual appearance of a chocolate and is veryimportant for consumer acceptance. More specifically, gloss refers tothe ability of the surface of a chocolate product to reflect incidentlight giving a “shiny” or “glossy” appearance. Gloss can be measured ina variety of ways both visually and instrumentally.

The gloss data described herein was determined using the TricorGlossmeter Model 801A. The products to be measured were held in theholder in the measurement chamber such that the surface to be measuredis at the same level relative to the light source and camera for allproducts. The meter is calibrated prior to each use using the TricorGloss standard reference plate which has a defined gloss level of 255.The measurement evaluated is the average gloss of the 5% brightestpixels with a threshold of 1. Typical subjective gloss values as relatedto Tricor measured gloss values are compared in Table I set forth below:

TABLE I Subjective Gloss Reading Excellent >190 Good 175 to 189 Fair 160to 174 Min. Acceptable 150 Poor 149 and below

23. The term “glossy” refers to a chocolate having an acceptable gloss,i.e., not dull, substantially uniform, etc. Although a relativelysubjective term, the use of the term is well known to those skilled inthe art.

24. Viscosity. Chocolate displays non-Newtonian rheology and cannot betotally characterized by a single rheological measurement point. Despitethis, apparent viscosity is a simple measure of viscosity useful for theevaluation of tempered and untempered chocolates and their suitabilityfor operations such as enrobing and molding. The measurement of apparentviscosity can be accomplished by many methods. The method used hereinfor apparent viscosity measurements is as follows: The chocolate ismaintained at the desired measurement temperature. The viscosity ismeasured using a Brookfield viscometer Model RV [Brookfield Co.,Brookfield, Mass.] equipped with a “B” size T-spindle (approximately36.4 mm cross-bar) and operating at 4 RPM. The spindle is immersed inthe chocolate to be measured and allowed to rotate three times. Thereading is taken after the third rotation and multiplied by 1000. Theresultant value is the apparent viscosity in centipoise.

25. The term “forming” includes decorating, shaping, embossing or anyother methods of producing a chocolate having a desired shape, form orappearance.

26. The term “shape” refers to any three-dimensional forms includingcubic shapes, animal shapes, etc.

27. The term “shaped chocolate product” as used herein refers to anydiscrete chocolate confection, as opposed to a continuous chocolateproduct such as a web product, a string product, or a connected seriesof repeating chocolate intermediate units which must be subsequentlyseparated during processing.

28. The term “deposit” as used herein in respect to “depositing onto asurface” refers to any means of causing a mass to be situated on thesurface. Such means can include but are not limited to, for example,dropping, extruding, coating, depositing, pouring, co-depositing, dualdepositing, and multiple depositing. Multiple depositing includes two ormore deposits in sequence, concurrently, or in a combination. Multipledepositing further includes depositing two or more compositions.Multiple depositing, in another sense, also includes depositing two ormore units in sequence, concurrently, or in a combination.

29. The term “deposit surface” refers to any surface on which a mass isdeposited.

According to the present invention, a shaped/formed or embossedchocolate product is made by contacting chilled forming, shaping orembossing device onto a mass of at least one surface of a chocolatecomposition comprising a liquid fat phase to form a set or semi-set(sufficiently solid to maintain shape) chocolate product of a specificshape or having a specific design embossed on the contacted surface. Theinvention provides the unique ability to make a “molded-type” product onan enrobing line or depositing process. Surprisingly, it has beendiscovered that a high definition embossed image or intricate orcomplicated shape can be made using a chilled shaping/forming orembossing device. For example, fine print, or pattern or design can beembossed onto the surface and/or the entire mass shaped into a desiredthree-dimensional form. Furthermore, it is believed that theformed/shaped or embossed intricate images may be as detailed asphotographic or holographic images. In addition, the shaping/forming orembossing can be accomplished rapidly without the use of a mold atadvantageously high production rates.

The present invention results in a set product that contains stable fatcrystals in the fat phase of the composition. Since the chocolate istypically kept or stored at room temperature, any unstable fat crystalswill readily transform to the more thermodynamically stable phases. Incontrast, chocolate compositions (typically non-standardized chocolate)are sometimes directly applied onto a frozen product (i.e., ice cream)to form a chocolate enrobed product. These chocolates do not formcompositions wherein substantially all the fat is in the stable formsince the product is kept frozen and therefore the unstable fat crystalsdo not transform into the stable forms. In fact, unlike confectionsstored at room temperature or ambient conditions, the chocolate coatingson frozen products are intended to primarily contain unstable fatcrystals to deliver a chocolate composition with low temperature meltingcharacteristics, complimentary to frozen fillings such as ice cream. SeePCT WO 94/07375 to Cebula, page 3, lines 11-12.

Therefore, the inventive method preferably results in a set chocolatecomprising stable fat crystals and unstable fat crystals. That is, theset chocolate should comprise a fat matrix containing fat crystals ofthe polymorph Form V, Form VI or mixtures thereof. Preferably, the setchocolate results in a finished confection as delivered to the consumerwith substantially the same melt profile as a conventionally processedchocolate confection.

Furthermore, another aspect of the invention relates to the ability toprovide acceptable gloss with the chilled forming/shaping or embossingdevice. This is achieved by providing a formed/shaped or embossedchocolate having planar surfaces and/or sharp edges to provideacceptable gloss perception. The gloss of a chocolate product is veryimportant for consumer acceptance.

An interesting comparison can be made with molded chocolate products,which when properly processed are typically considered to be glossierthan their enrobed counterparts. According to yet another aspect of theinvention, the process parameters are controlled to provide ashaped/formed or embossed product having acceptable gloss. As describedabove, factors that affect the gloss of a chocolate mass are (i) thecontact time with the forming/shaping or embossing device, (ii) thetemperature of the forming/shaping or embossing device, and (iii) therewarming process caused by internal and external heat. Accordingly, theprocess parameters that affect such factors can be controlled to provideacceptable gloss.

Accordingly, one aspect of the invention relates to controlling (i) thetemperature of the chocolate composition, (ii) the temperature of thechilled forming/shaping or embossing device, and (iii) the time ofcontact and temperature of cooling of the mass after contacting toaffect the rewarming of the surface of the chocolate to improve thegloss. One method of achieving this is by contacting the chocolate withthe chilled device to the chocolate for a brief period of time (forexample, less than 1 second) sufficient to form a very thin skin ofsolidified chocolate layer thick enough to retain the desired shape.However, since the solidified layer is thin, the inner portion of thechocolate, which is still warm, e.g., around 25° C., is able to warm andpotentially partially melt the set skin to an extent sufficient toexpress fat on the surface without losing the shape or form of thechocolate mass.

One embodiment of the invention relates to controlling the processparameters to provide a solidified skin that is thin enough to allow theinner warm portions of the chocolate mass to warm the surface to anextent that the retracted fat flows without losing the shape of theskin. If the solidified skin is too thick, the inner portion of thechocolate will not warm the solidified outer surface layer to allow thefat to express on the surface. The resultant set surface is likely tohave poor gloss. Alternatively, if the solidified skin is too thin, theinner warm portions will warm the solidified skin too much and cause theentire solidified skin to melt and lose its form. The ability to retainthe form or detailed decoration of the chocolate and provide acceptablesurface gloss is a surprising and unexpected result. By controlling theprocess parameters, a glossy decorated or shaped chocolate confectioncan be rapidly produced.

According to another embodiment, the surface of the rapidlyshaped/formed or embossed chocolate may be warmed by using external heatby convection and/or radiation to improve the gloss of the rapidlyformed/shaped or embossed product.

In one embodiment of the invention, rapid release of the chocolate fromthe surface of the forming/shaping or embossing device is accomplishedby controlling the surface energy of the device. This can beaccomplished, as described above, by (i) lowering temperature, (ii)selecting low surface energy materials, or (iii) coating with lowsurface energy materials as described in U.S. Provisional Application“Improved Molding Process”, FCH&S Docket No. 2280.2360, filedcontemporaneously, and incorporated herein by reference in its entirety.The term “low surface energy” refers to those surface energy values thatpromote release, as described in the above referenced application. Bylowering the surface energy of the device, the wetting of the surface bythe chocolate is reduced. This reduces the adhesive strength of thechocolate to the device relative to the cohesive strength of thechocolate provided by the rapid solidification of the chocolate at thelow temperature.

According to one preferred embodiment, the chocolate is deposited ontoan edible product, shaken to distribute the chocolate around the topsurface of the edible product and subsequently contacted with thechilled shaper/former or embosser to form the shaped/formed or embossedchocolate product.

According to one preferred embodiment, two or more compositions may beco-deposited onto the belt and shaped/formed to form a multi-componentfood product or filled chocolate product. For example, an edible mass isformed by enrobing or depositing the chocolate composition onto anedible center prior to contacting the edible mass with the chilledforming/shaping or embossing device. The edible center may comprise anedible composition selected from nougat, truffle, peanut butter,caramel, praline, nuts, marshmallow, fudge, puffed grains, cookie,biscuit, wafer, turkish delight, fondants and mixtures thereof. Usingthe present invention, novel chocolate coated products can be producedsince the center portion can be deposited before the chocolate. Duringconventional methods, a chocolate shell is formed in a mold cavity. Theresultant chocolate shell is then filled with an edible mass to form achocolate coated confection. If the edible mass needs to be maintainedat elevated temperature in order for it to flow (i.e., be deposited), itcannot be used as the center of the chocolate confection since it willmelt the chocolate after being deposited into the chocolate shell. Thepresent invention provides the advantage of being able to first deposita highly viscous center at elevated temperatures, cool the deposit massto a temperature before the solidification temperature of the chocolate,deposit the chocolate onto the cooled mass and finally contact thechocolate coated mass with a chilled former to form a novel high qualitymolded confection.

According to another preferred embodiment, two or more chocolate orfat-containing compositions are co-deposited side by side in contactwith one another and a forming/shaping device is contacted with thecomposite mass and twisted, spun, twirled or otherwise moved while incontact with the mass to form a spiral or other type of design as aresult of the mixing or co-mingling of the two or more compositions. Forexample, white chocolate and dark chocolate are co-deposited onto asurface to form a mass containing both white and dark chocolate. Achilled former/shaper is contacted with the mass and rotated to form aformed/shaped product having a swirl type design.

Alternatively, a first chocolate composition can be deposited onto asurface and a second chocolate composition sprayed, thinly coated orsplattered onto the first chocolate composition to form a compositemass. The chilled former/shaper or embosser can then be contacted withthe mass to form an formed/shaped or embossed composite mass.

Another aspect of the invention, relates to an apparatus for contactingthe chilled device with the chocolate composition. The apparatus can belocated in the enrober, in a transition zone between the enrober andcooling tunnel or within the cooling tunnel. In a preferred embodiment,the apparatus includes a chilled ring-sealing device to contain thechocolate prior to or during application of the chilled former/shaper orembosser.

The operating temperature of the chilled forming, shaping, or embossingdevice is preferably below about 10° C., advantageously less than 5° C.,even better less than 0° C. and still more preferred less than −5° C.Even lower temperatures such as below −10° C., even better below −15° C.and below −20° C. may be used to produce products having even furtherimproved properties.

The rapid setting of the contacted surface occurs in a period of timesubstantially less than the cooling time of conventional moldingmethods. Preferably, the contact time of the chilled device onto thechocolate surface is less than 1 minute, advantageously less than 45seconds, even better less than 30 seconds and most preferred less than20 seconds. Shorter cooling times such as less than 10 seconds minute oreven less than 5 seconds may be used with suitable chocolatecompositions.

According to another preferred embodiment, the melted chocolatecomposition is first enrobed onto an edible product, contacted with achilled former/shaper or embosser and subsequently rapidly orconventionally cooled to form a set chocolate coating.

Alternatively, the chocolate composition is deposited onto an ediblecenter and/or a conveyor belt or tray or the like, contacted with thechilled former/shaper or embosser and transported into the rapid coolingzone or conventional cooling tunnel. According to another embodiment,the chocolate is contacted with the chilled former/shaper or embosserimmediately after entering a cooling tunnel. Furthermore, according toanother embodiment the forming/shaping or embossing is accomplishedwithin the tunnel after significant solidification of the chocolate hasoccurred. In this instance, warming of the surface of the chocolate iscarried out by radiative or convective means prior to the inventiveforming/shaping or embossing step.

Another aspect of the invention relates to the ability to achieve goodretention of the shape of the contacted surface using, for example,colder formers/shapers or embossers, longer contact times and/orsubsequent rapid cooling treatment. Although the shaped/formed orembossed product can be subsequently cooled by conventional cooling toprovide acceptable retention of detail, a preferred aspect of theinvention relates to the ability to provide high quality shaped ordecorated products using rapid cooling. Conventional cooling may resultin less decoration retention (see FIG. 1(a)), whereas the rapid coolingresults in an improved setting of the embossed surface and excellentfine detail retention as a result of the rapid setting of at least theouter surface layer of the product (See FIG. 1(b)). Either conventionalcooling or rapid cooling can be used to set the formed chocolates.According to the present invention, the formed/shaped or embossedproducts are preferably set by rapid cooling as set forth in ApplicationSerial No. 08/789,902, filed Jan. 11, 1997, and herein incorporated byreference.

Alternatively, using (i) rapid chilled forming/shaping or embossing,and/or (ii) rapid cooling allows for the use low or ultra low temperchocolates. This allows for the use of reduced fat chocolates since thelower temper will provide lower viscosities. The use of low andultra-low temper and methods of providing chocolates having these temperlevels with seeding agents is described in U.S. patent application Ser.No. 08/782,903, filed Jan. 11, 1997, and herein incorporated byreference. The chocolate composition can either be tempered byconventional methods or seeded with a seeding agent. Another embodimentof the invention relates to the use of seeded chocolates having higheraverage mass temperatures at the time of being contacted with thechilled device to provide better wetting of the chilled device and/or areduction in the retraction of fat at the surface. Various methods offormulating seeded chocolates suitable for use in chilledforming/shaping or embossing according to the invention are described inU.S. patent application Ser. No. 08/782,903.

Rapid forming/shaping or embossing chocolate compositions having higherbulk temperatures allows for contacting with chilled devices to resultin a formed/shaped or embossed chocolate product having acceptablesurface gloss. The ability to contact chilled devices with a temperedchocolate having a higher temperature enables the hot tempered chocolateto temporarily warm the contacted surface of the chilled device therebyreducing or eliminating the fat retraction from the surface of thedevice. Moreover, the hot chocolate wets the chilled surface of thedevice better. The result is the ability to rapidly produceformed/shaped or embossed products having acceptable gloss. As the hotseeded chocolate is contacted with the chilled former/shaper orembosser, the chocolate temporarily warms the contacted surface toprovide good wetting. After the seeded chocolate is contacted and wetsthe chilled forming/shaping or embossing device, the chilled devicerapidly solidifies the chocolate mass rapidly forming a glossyshaped/formed or embossed product.

Referring to FIG. 2, according to one embodiment of the presentinvention, an edible mass 12 is deposited onto a deposit surface 11 of asubstrate 10. A forming member 13 having a chilled contacting surface 16is contacted to edible mass 12, thereby at least partially solidifyingan outer surface layer of edible mass 12 to form a shaped edible product15.

Referring to FIG. 3, according to another embodiment of the presentinvention, an edible mass 22 is deposited onto a deposit surface 21 of asubstrate 20. A forming member 23 having a chilled contacting surface 26is contacted to edible mass 22, thereby at least partially solidifyingan outer surface layer of edible mass 22 to form a shaped edible product25. In this embodiment, forming member 23 is not brought into contactwith deposit surface 21.

Referring to FIG. 4, according to yet another embodiment of the presentinvention, an edible mass 32 is deposited onto a deposit surface 31 of asubstrate 30. A containment member 34 is brought into contact withdeposit surface 31 to bound edible mass 32. Forming member 33 having achilled contacting surface 36 is contacted to edible mass 32, thereby atleast partially solidifying an outer surface layer of edible mass 32 toform a shaped edible product 35. In this embodiment, containing member34 prevents edible mass 32 from overextending a preset boundary.Containing member 34 need not be in contact with edible mass 32 prior tothe action of forming member 33.

In the above example, the action of the forming member can stop short ofthe forming member contacting the deposit surface.

It is preferred that containing member 34 be chilled. Otherwise, theprocess time is lengthened. It is preferred that containing member 34 ischilled to below about 10° C., more preferably to below about 0° C.,even more preferably below about −15° C. The temperature of containingmember 34 can be different from the temperature of chilled contactingsurface 36. If containing member 34 is chilled, the contact time shouldbe controlled to avoid excessive solidification of edible mass 32 priorto the action of forming member 33.

Referring to FIG. 5, according to an embodiment of the presentinvention, a containment member 44 is brought into contact with adeposit surface 41, of a substrate 40, to bound an edible mass 42.Edible mass 42 is deposited onto deposit surface 41 and bound bycontainment member 44. Containment member 44 is removed, and a formingmember 43 having a chilled contacting surface 46 is contacted to ediblemass 42, thereby at least partially solidifying an outer surface layerof edible mass 42 to form a shaped edible product 45.

In the above example, the action of the forming member can stop short ofthe forming member contacting the deposit surface.

It is preferred that containing member 44 be chilled. Otherwise, theprocess time is lengthened. It is preferred that containing member 44 ischilled to below about 10° C., more preferably to below about 0° C.,even more preferably below about −15° C. The temperature of containingmember 44 can be different from the temperature of chilled contactingsurface 46. If containing member 44 is chilled, the contact time shouldbe controlled to avoid excessive solidification of edible mass 42 priorto the action of forming member 43.

Referring to FIG. 6, according to another embodiment of the presentinvention, a containment member 54 is brought into contact with adeposit surface 51, of a substrate 50, to bound an edible mass 52.Edible mass 52 is deposited onto deposit surface 51 and bound bycontainment member 54. A forming member 53 having a chilled contactingsurface 56 is contacted to edible mass 52, thereby at least partiallysolidifying an outer surface layer of edible mass 52 to form a shapededible product 55.

In the above example, the action of the forming member can stop short ofthe forming member contacting the deposit surface.

It is preferred that containing member 54 be chilled. Otherwise, theprocess time is lengthened. It is preferred that containing member 54 ischilled to below about 10° C., more preferably to below about 0° C.,even more preferably below about −15° C. The temperature of containingmember 54 can be different from the temperature of chilled contactingsurface 56. If containing member 54 is chilled, the contact time shouldbe controlled to avoid excessive solidification of edible mass 52 priorto the action of forming member 53.

Referring to FIG. 7, according to another embodiment of the presentinvention, a deposit surface 61 of a substrate 60 includes a recess 64.An edible mass 62 is deposited onto deposit surface 61 such that ediblemass 62 is bound by recess 64 and extends above deposit surface 61. Aforming member 63 having a chilled contacting surface 66 is contacted toedible mass 62, thereby at least partially solidifying an outer surfacelayer of edible mass 62 to form a shaped edible product 65. In thiscase, recess 64 serves to contain edible mass 62 to prevent edible mass62 from extending beyond a predetermined boundary. In anotherembodiment, not shown, recess 64 can serve to impede the flow of ediblemass 62 during the action of forming member 63, thereby preventingshaped edible product 65 from extending beyond a predetermined boundary.

Referring to FIG. 8, according to an embodiment of the presentinvention, a deposit surface 71 of a substrate 70 includes a ridge 74.An edible mass 72 is deposited onto deposit surface 71 such that ediblemass 72 is bound by ridge 74 and extends above deposit surface 71. Aforming member 73 having a chilled contacting surface 76 is contacted toedible mass 72, thereby at least partially solidifying an outer surfacelayer of edible mass 72 to form a shaped edible product 75. In thiscase, ridge 74 serves to contain edible mass 72 to prevent edible mass72 from extending beyond a predetermined boundary. There can be amultitude of ridges. The ridges can be of any convenient shape andgeometry.

In another embodiment, referring to FIG. 9A, a deposit surface 81 of asubstrate 80 includes a ridge 84. An edible mass 82 is deposited ontodeposit surface 81 such that the flow of edible mass 82 is impeded byridge 84 and edible mass 82 extends above deposit surface 81. A formingmember 83 having a chilled contacting surface 86 is contacted to ediblemass 82, thereby at least partially solidifying an outer surface layerof edible mass 82 to form a shaped edible product 85. In this case,ridge 84 serves to impede the flow of edible mass 82 during the actionof forming member 83, thereby preventing shaped edible product 85 fromextending beyond a predetermined boundary.

Referring to FIG. 9B, in an embodiment of the present invention, adeposit surface 81′ of a substrate 80′ includes a textured surface 84′.An edible mass 82′ is deposited onto deposit surface 81′ such that theflow of edible mass 82′ is impeded by textured surface 84′ and ediblemass 82′ extends above deposit surface 81′. A forming member 83′ havinga chilled contacting surface 86′ is contacted to edible mass 82′,thereby at least partially solidifying an outer surface layer of ediblemass 82′ to form a shaped edible product 85′. In this case, texturedsurface 84′ serves to impede the flow of edible mass 82′ during theaction of forming member 83′, thereby preventing shaped edible product85′ from extending beyond a predetermined boundary.

Referring to FIG. 9C, in another embodiment of the present invention, adeposit surface 81″ of a substrate 80″ includes a chilled portion 84″.An edible mass 82″ is deposited onto deposit surface 81″ such that theflow of edible mass 82″ is impeded by chilled portion 84″ and ediblemass 82″ extends above deposit surface 81″. A forming member 83″ havinga chilled contacting surface 86″ is contacted to edible mass 82″,thereby at least partially solidifying an outer surface layer of ediblemass 82″ to form a shaped edible product 85″. In this case, chilledportion 84″ serves to impede the flow of edible mass 82″ during theaction of forming member 83″ because the cooler temperature of chilledportion 84″ partially sets edible mass 82″ and slows the flow of ediblemass 82″ during the action of forming member 83″, thereby preventingshaped edible product 85″ from extending beyond a predeterminedboundary.

Referring to FIG. 10A, according to an embodiment of the presentinvention, at least two containment members 94 a and 94 b are broughtinto contact with a deposit surface 91, of a substrate 90, to bound anedible mass 92. Edible mass 92 is deposited onto deposit surface 91 andbound by containment members 94 a and 94 b. Containment members 94 a and94 b include topological features 97 a and 97 b respectively. A formingmember 93 having a chilled contacting surface 96 is contacted to ediblemass 92, thereby at least partially solidifying an outer surface layerof edible mass 92 to form a shaped edible product 95. Topologicalproduct features 98 are formed correspondingly to topological features97 a and 97 b.

It is preferred that containing members 94 a and 94 b be chilled.Otherwise, the process time is lengthened. It is preferred thatcontaining members 94 a and 94 b are chilled to below about 10° C., morepreferably to below about 0° C., even more preferably below about −15°C. The temperature of containing members 94 a and 94 b can be differentfrom the temperature of chilled contacting surface 96. If containingmembers 94 a and 94 b are chilled, the contact time should be controlledto avoid excessive solidification of edible mass 92 prior to the actionof forming member 93.

Referring to FIG. 10B, according to another embodiment of the presentinvention, at least two containment members 94 a′ and 94 b′ are broughtinto contact with a deposit surface 91′, of a substrate 90′, to bound anedible mass 92′. Edible mass 92′ is deposited onto deposit surface 91′and bound by containment members 94 a′ and 94 b′. Containment members 94a′ and 94 b′ each include an undercutting feature 99. A forming member93′ having a chilled contacting surface 96′ is contacted to edible mass92′, thereby at least partially solidifying an outer surface layer ofedible mass 92′ to form a shaped edible product 95′. Extending overhangportions 100 are formed correspondingly to undercutting feature 99.

It is preferred that containing members 94 a′ and 94 b′ be chilled.Otherwise, the process time is lengthened. It is preferred thatcontaining members 94 a′ and 94 b′ are chilled to below about 10° C.,more preferably to below about 0° C., even more preferably below about−15° C. The temperature of containing members 94 a and 94 b can bedifferent from the temperature of chilled contacting surface 96′. Ifcontaining members 94 a′ and 94 b′ are chilled, the contact time shouldbe controlled to avoid excessive solidification of edible mass 92′priorto the action of forming member 93′.

The substrate can be any convenient supporting material such as, forexample, rubber, polymer, metal, paper, inorganic, or organic material.The substrate can be an edible composition. The substrate can bestationary, moving, or intermittently moving. The substrate can be amovable component such as, for example, a belt, tray, sheet, wheel, cog,cam, or follower. The deposit surface, can be any convenient surfaceincluding, for example, a surface of a product intermediate or of anon-edible container.

The action of the containing member, containing feature, flow impedingmember, or flow impeding feature can occur before, during, or after theedible mass is deposited onto the deposit surface. Further, the actionof the containing member, containing feature, flow impeding member, orflow impeding feature can occur before or during the action of theforming member.

The containing member and the forming member can each be composed ofmore than one part or component. Such parts or components can beconnected to each other movable, slidably, and/or rotatably, by anyconvenient means such as, for example, by hinges, pins, channels,resilient portions, memory portions, environmentally responsiveportions, springs, mating portions, etc. Each component can be anyconvenient shape, made of any convenient material. As shown by FIGS. 10Aand 10B, such multicomponent members allow topological features to beformed/shaped or embossed which would be unavailable from a singlecomponent member.

The point of contact of the containing member with the surface caninclude any convenient seal such as, for example, a resilient portion,gasket, mating portion, O-ring, or gland. The seal can be at the end ofthe containing member proximate to the surface that the containingmember contacts, on the surface itself, or on both. The seal can becomplete in order to completely bound the deposited edible mass, or theseal can be partial. If the seal is partial, the containing memberserves to impede the flow of the edible mass, during the action of theforming member, effective to limit the product of the action of theforming member to a predetermined bound.

In general, the deposited edible mass extends above the deposit surface.If the edible mass is deposited into a recess volume, the edible massextends above the depth of the recess in order to extend above thedeposit surface. It is only necessary for the deposited edible mass toextend above the region of the deposit surface proximate to the ediblemass; that is, the edible mass need not extend above a surface featureof the deposit surface located at a distance, from the edible mass,which does not affect the relationships between the forming member, theedible mass, the deposit surface, and any containment means.

In general, it is preferable to control humidity in order to control thedew point to avoid or control condensation on the forming member and onthe containing member when chilled. The containing member and/or theforming member can be insulated, although such insulation is notrequired.

In general, any surface described above can be selected, or modified tohave a surface energy effective to promote release.

The containing member can include more than one surface and can includemore than one vertex. The containing member can operate in concert withthe forming member to produce various three dimensional effects such asan undercut to the edible product. The containing member can operate tocause three dimensional features on the edible product.

In general, in all of the above cases, the flow of the edible mass canbe controlled as described. However, in addition, the rheology of theedible mass can be controlled in order to limit the flow of thedeposited edible mass. The yield value can be controlled, as is known toone of ordinary skill in the art be any convenient method such as, forexample, by aeration or by modification of the emulsifier or fatcontent. In fact, FIG. 9C demonstrated how cooling affects the yieldvalue effective to control the flow of the edible mass.

EXAMPLES

The following examples are illustrative of some of the products andmethods of making the same falling within the scope of the presentinvention. They are, of course, not to be considered in any waylimitative of the invention. Numerous changes and modification can bemade with respect to the invention.

Example 1

A milk chocolate composition is prepared using the formulation in Table1-A below:

TABLE 1-A Milk Chocolate Formulation Sugar 50.00% Cocoa Butter 20.49%Whole Milk Powder 18.00% Chocolate Liquor 11.00% Lecithin 0.50% Vanillin0.01%

The chocolate mixture is refined to reduce the solid particle sizes to25 microns (by micrometer) and then loaded into a Petzholdt Conge. Thechocolate is dry conged for 6 hours after which lecithin is added. Thechocolate is then spun in the conge for 30 minutes. The conged chocolateis transferred into a tank where additional lecithin and cocoa butterare added (standardization) to achieve an apparent viscosity of 20,000cps at 45° C. The standardized chocolate is then tempered in acontinuous Sollich Solltemper-Turbo Model MSV3000 where the chocolate iscooled from 45° C. to 28° C. with aggressive shear to produce cocoabutter crystals of stable and unstable polymorphs. The temperedchocolate is warmed slightly in the last section of the Solltemper to31° C. to melt out unstable crystals. The tempered chocolate is at 31°C. and has a temper level of 6 CTU (°F) and −0.5 slope as determined byTricor Tempermeter Model 501. The chocolate is then pumped to theenrober.

The centers to be coated with chocolate have a chewy nougat bottom layerand soft caramel top layer. The nougat has composition set forth inTable 1-B (below) and is prepared by the method described in Minifie,3rd Edition, pg. 578-580.

TABLE 1-B Chewy Nougat Formulation Egg Albumen 0.37% Sugar 43.22 GlucoseSyrup 36.63% Water 19.78%

The caramel composition is set forth in Table 1-C prepared in the mannersimilar to that described in Minifie, 3rd Ed., pp 533-537.

TABLE 1-C Soft Caramel Formulation Corn Syrup 40.00% Sweetened Cond.Whole Milk 37.40% Sugar 13.50% Milk Butter 5.19% Water 3.40% Salt 0.50%Flavorings 0.01%

The caramel/nougat centers have an average temperature of 24° C. at timeof enrobing. The caramel/nougat centers comprise a nougat layer (10 mmthick) and a caramel layer (4 mm thick) applied onto the top surface ofthe nougat. The overall size of the center is 14 mm high and 20 mmsquare. The centers are coated with tempered milk chocolate in acontinuous enrober as described in Minifie, 3rd Ed., pages 216-218. Theamount of chocolate enrobed onto the center is 35% by weight of thetotal finished chocolate confection with an average thickness of about 2mm.

The enrobed centers coated with liquid tempered chocolate aretransferred from the wire belt to a solid polyurethane coated belt whichpasses into a temperature and humidity controlled embossing zonemaintained at a temperature of 31° C. and a dewpoint of −24° C.

In the embossing zone, the belt passes over a rigid flat plate on whichembossing occurs. The rigid flat plate is wide enough to support thebelt and coated centers through the entire embossing cycle. The centersare aligned prior to entering the enrober and maintain the alignmentthrough the discharge to present an orderly rank and file to theembossing section. The embosser is comprised of a refrigerated panel towhich is affixed solidly, and with good heat transfer contact, anembossing plate comprised of designs upon a plane background (convex) orforeground (concave). The embossing plate, which may be readilyinterchanged with those of other designs, has a plurality of individualembossing regions for embossing individual confections. The embossingregions on the plate are decorated with a repeated pattern of protrudingstars of diameters of 3, 4 and 5 mm. The refrigerated panel is cooled byglycol which has an operating temperature such that the exposed surfaceof the embossing plate is maintained at −20° C. The entire embosserassembly, that is the embossing plate and the refrigerated panel ismounted in a frame. The frame may be rapidly and precisely drivensimultaneously in both the vertical (up and down), horizontal (with andagainst the direction of travel of the coated bars on the belt) andside-to-side (across the direction of travel for fine alignmentadjustment) directions through the application of servo motor drivemechanisms. The embossing plate is wide enough to cover the width of thebelt carrying the coated centers and contains a number of embossingregions enabling the simultaneous embossing of a multiplicity ofproducts.

Starting the embossing cycle, the embossing assembly moves downwardand/or horizontally such that upon contacting the tops of the coatedcenters there is no relative speed between the embossing plate and thecoated centers. The embossing assembly travels with, and in contact withthe chocolate on the tops of the coated centers for 1 second after whichthe embossing plate retracts and travels back to position to restart thecycle. The embossing plate is of sufficient dimension in the directionof travel to provide the contact time required to emboss the chocolatewhile allowing transit time to return to the beginning of the cycle. Theembossed surface of the chocolate rewarms slightly due to heat transferfrom the warmer lower layers of the chocolate and from the environmentjust prior to, and in, the cooling tunnel. This warming causes some ofthe fat which had been set as unstable crystals from the cold embossingin the chocolate surface layers to melt. This may be observed as aslight sheen on the embossed surface. This partial melting results inthe slight softening of the surface, improving the finished gloss. Theembossed, coated centers then enter a chocolate cooling tunnel.

The cooling tunnel is comprised of three sections. The first sectioncomprises an environment with an air temperature of 17° C. with anaverage H-value of 35 w/m² ° C. The coated centers are carried by theconveyor belt over platens under the conveyor belt in the first sectionof the tunnel. These platens are cooled to 15° C. by recirculatingcooling media and set the chocolate on the bottoms of the coated centersso that the pieces release from the conveyor belt in 3 minutes to enablethe transfer of the coated centers to the second cooling tunnel sectionbelt. The second section of the tunnel has an operating temperature of12° C. and an H-value of 35 w/m²° C. The coated centers are in thesecond section of the tunnel for 5 minutes. The last section of thetunnel is 2 minutes long and has an operating temperature of 18° C. andan H-value of 35 w/m²° C. to warm the surface of the set chocolate sothat the surface is above the dewpoint of the environment upon exitingthe tunnel. The total time in all three sections of the cooling tunnelis 10 minutes. The resultant finished chocolate confection exiting thetunnel has a fair to acceptable gloss, with some loss of detail due tothe rewarm effect immediately after embossing.

Example 2

Caramel/nougat centers comprised as set forth in Example 1 are enrobed,embossed and cooled as set forth in Example 1 with the exception of theembossing plate contact time. In this example, the contact time is 3seconds. The design detail is maintained better than Example 1 due tothe reduced effect of the surface rewarm from the inner warmer portiondue to the thicker layer of set chocolate created by the longer contacttime. This reduces the subsequent flow of the embossed features. Thisresults in a sharper design detail but only acceptable gloss.

Example 3

Centers comprised as set forth in Example 1 are enrobed, embossed andcooled as set forth in Example 1 with the exception of the embossingplate contact time. In this example, the contact time is optimized to2.1 seconds. The optimized time for a given plate temperature is afunction of, among many things, chocolate type, environmental conditionsin the embossing zone and setting rate in the cooling tunnel. Theoptimized time results in the optimum design detail retention, whiledelivering acceptable gloss.

This is achieved by controlling the thickness of the set layer byvarying either the contact time and/or surface temperature of theembosser. The optimized contact time results in a set layer that is thinenough to allow the inner warm portions to warm the fat within the setlayer, thereby providing fat to be expressed on the surface andproviding acceptable gloss, but low enough to prevent flow of thechocolate that would result in loss of detail. This optimization can beachieved without undue experimentation by simply varying the processparameters to provide the optimal combination of gloss and shaperetention.

Example 4

Centers comprised as set forth in Example 1 are enrobed, and embossed asset forth in Example 1. The embossed coated centers then enter thecooling section of the tunnel. The environment in the tunnel is −15° C.with a dewpoint of −20° C. The average H-value above the belt in thetunnel is 125 w/m²° C. The conveyor belt rides on platens cooled byrefrigerated liquid to a temperature of −15° C. The platens extend intothe tunnel to the point where the coated centers and belt have beenexposed to the cold platens for 1 minute. The remainder of the tunnel, 2minutes, is not equipped with cooling platens. The total time on thecooling section of the tunnel is 3 minutes. Upon exiting the coolingsection, the cooled coated centers release from the belt, transfer toanother conveyor and then enter the rewarm zone. The rewarm zone has acontrolled atmosphere of 10° C., with a dewpoint of −20° C. and anaverage H-value of 50 w/m²° C. The surface temperature of the finishedchocolate confection is raised to 9° C., which is above the dewpoint ofthe environment at the exit of the rewarm zone. In comparison withExample 1, aggressive cooling reduces the effect of the surface rewarmand subsequent flow at the expense of less liquid fat on the surface.This results in improved detail with somewhat less gloss.

Example 5

Caramel/nougat centers comprised as set forth in Example 1 are enrobed,embossed and cooled as set forth in Example 3, with a contact time of 3seconds to give good design detail. This generally results in onlyacceptable gloss. In order to optimize the balance of gloss to retentionof design detail as described in Example 3, a step of active surfacerewarm is added prior to the cooling tunnel. An air plenum delivering anH-value of 75 w/m²° C. with an air temperature of 31° C. for 10 secondsis interposed between the embossing and the cooling tunnel as set forthin Example 4. This combination allows for precise control of the factorseffecting both gloss and design detail.

Example 6

The minimization of contact time provides an operational advantage inthat the reduced contact time allows for either a smaller embossingassembly or longer recycle time (when the embossing assembly returns tostart the embossing cycle) or an optimized combination of smaller plateand reduced return transit time. This example illustrates the impact ofthe variables on the required contact time.

Centers are enrobed as set forth in Example 1. The coated centers areembossed and cooled by a variety of conditions as set forth in Table 6-ABelow:

TABLE 6-A Plate Contact Plenum Time @ Temperature Time (sec) 31° C.(sec) −10° C. 3.9 5 −15° C. 3.1 6 −20° C. 2.5 7 −30° C. 2.0 9 −40° C.1.6 10 

Cooling tunnel conditions are as set forth in Example 4.

Example 7

Centers are prepared, enrobed, embossed and cooled as set forth inExample 5. The pattern of the embosser plate, instead of a “wallpaper”type pattern without specific registration with the coated center,comprised two individual patterns on the surface of the embosser. Thetwo patterns are embossed upon the coated centers such that the designis in registration. That is to say that, at the moment of contact of theembossing plate with the coated centers, the patterns are centered uponthe coated centers. This example allows for resultant finished chocolateconfections with multiple designs with gloss and design detail similarto molded chocolate confections from an enrobing production line.

Example 8

Caramel/nougat centers are formed comprising a nougat layer (11 mmthick) and a caramel layer (5 mm thick) applied onto the top surface ofthe nougat. The overall size of the center is 100 mm long by 25 mm wideby 16 mm high. The centers are coated with tempered milk chocolate in acontinuous enrober as described in Minifie, 3rd Ed., pages 216-218.Enrobing is carried out such that the excess chocolate is removedpredominantly by shaking rather than impingement blowers. This resultsin a coating which preferentially remains on the tops of the centers.The amount of chocolate enrobed onto the center is 35% by weight of thetotal finished chocolate confection with an average side and bottomthickness of about 2 mm and a top thickness of about 3 mm.

The enrobed centers coated with liquid tempered chocolate aretransferred from the wire belt to a solid polyurethane coated belt whichpasses into a temperature and humidity controlled embossing zonemaintained at a temperature of 34° C and a dewpoint of −24° C. Thecoated centers are embossed by an embossing assembly comprising arefrigerated panel and decorated plate as set forth in Example 1 andcontrolled in register as set forth in Example 7. The refrigerated panelis cooled by Syltherm® (a silicon oil) such that the embossing surfaceof the decorated panel is maintained at a temperature of −34° C. Icetends to deposit on the embossing surface but is substantially removedeach cycle through contact with the warm chocolate. Although ice maybuild up on the non-insulated, non-contact surfaces of the panels, thisis minimized by design of the refrigerated plate and decorated plate.The design on the embosser face provides for deeper detail which isaccommodated by the thicker chocolate layer on the tops of the centers.

The dimensions of the internal radii of the design are critical for thegood release from the embosser. It is believed sharp corners are to beavoided and all radii should be 1.5 mm or greater. In addition, rightangles to the face of the embosser should be avoided. Release angles ofabout 8° or greater are sufficient. The chocolate is contacted forapproximately 2 to 3 seconds depending upon chocolate type and temperand the exact design on the embosser surface. After embossing, thesurface of the embossed chocolate is warmed for 5 to 15 seconds with airat a temperature of 34° C. and an H-value of 90 w/m²° C. The embossedcoated centers then enter a cooling tunnel as set forth in Example 4.The finished chocolate confection has a high detail, deep relief designwith acceptable gloss.

Example 9

Centers are prepared and enrobed as in Example 1. The coated centersenter a cooling tunnel as set forth in Example 4. The embossing sectionis positioned immediately or up to 20 seconds after the tunnel entrance.A roller or wheel is positioned over rigid cooling platens. The coolingplatens set the bottoms of the coated center as well as provide supportfor the embossing operation. The roller is adjustable up-and-down toaccommodate a variety of product heights, is chilled internally or bythe tunnel environment and driven such that the surface speed of thewheel matches that of the coated centers. The chilled roller isdecorated in a manner similar to the embossing plate set forth inExample 1 except that the design wraps around the circumference of theroller. The embossing section in the cooling tunnel is positioned suchthat the chocolate is partially set but remains fluid enough to allowinduced flow or forming. Alternatively, the chocolate, if set, may berewarmed by active surface rewarm as set forth in Example 5 prior toembossing.

As the embossing section is in a cooled environment and the chocolate ispartially set, the required contact time is reduced which allows the useof a wheel or roller with a necessarily limited contact time to form thedesign. If necessary, the embossed design on the coated centers may berewarmed by air or heaters as set forth in Example 5 internal to thetunnel. This is obviously at the expense of energy efficiency. Theembossed centers then continue in the tunnel as set forth in Example 4with operating conditions of −20° C., H-value of 110 w/m²° C. for atotal residence time of 3 minutes. The finished chocolate confection hasgood detail of design with acceptable gloss.

Example 10

Caramel/nougat centers are prepared enrobed and embossed as set forth inExample 1 except that the embosser surface temperature is operated at 9°C. In this example, with the stated embosser temperature, satisfactoryrelease of the chocolate from the embosser may only be accomplished withcontact times in excess of 10 or 20 seconds dependent upon chocolatetype, temper, embosser material and design, and environmentalconditions. Release is attempted in 10 seconds, and sufficientsolidification has not occurred in the chocolate to allow release fromthe surface of the embosser. The attempted release results in any or allof the following: detrimental chocolate surface disruption, severebuild-up of chocolate on the embosser plate leading to jams and pick-upof the product from the belt partially or completely thereby causingfurther jams of the mechanism.

Example 11

A milk chocolate composition is prepared using the formulation in Table11-A below:

TABLE 11-A Milk Chocolate Formulation Sugar 50.00% Cocoa Butter 20.49%Whole Milk Powder 18.00% Chocolate Liquor 11.00% Lecithin 0.50% Vanillin0.01%

The chocolate mixture is refined to reduce the solid particle sizes to25 microns (by micrometer) and then loaded into a Petzholdt Conge. Thechocolate is dry conged for 6 hours after which lecithin is added. Thechocolate is then spun in the conge for 30 minutes. The conged chocolateis transferred into a tank where additional lecithin and cocoa butterare added (standardization) to achieve an apparent viscosity of 20,000cps at 45° C. The standardized chocolate is then tempered in acontinuous Sollich Solltemper-Turbo Model MSV3000 where the chocolate iscooled from 45° C. to 28° C. with aggressive shear to produce cocoabutter crystals of stable and unstable polymorphs. The temperedchocolate is warmed slightly in the last section of the Solltemper to31° C. to melt out unstable crystals. The tempered chocolate is at 31°C. and has a temper level of 6 CTU (°F.) and −0.5 slope as determined byTricor Tempermeter Model 501.

The tempered chocolate is then deposited in 7 g portions onto acontinuously moving thin plastic belt (Burrell Polycool PC4) in auniform pattern of rows and columns. There are 40 portions across thebelt and 5 portions per deposit in the direction of travel for a totalof 200 portions per deposit. The depositor operates repeatedly so that acontinuous pattern of portions is deposited on the belt. The chocolateportions are then transported on the belt to the forming section. Theportions are roughly flattened spheres as there is some settling intransit. The forming section is located in a controlled environment witha temperature of −21° C. and a dewpoint of −24° C. The belt rides on arigid flat plate which supports the portions during the forming step.The plate may be cooled as necessary to set the bottoms in the mannerset forth for the cooling tunnel platens in Example 1 (15° C.) and 4(−15° C.). The forming assembly is comprised of multiple refrigeratedforming heads in positions corresponding to the configurations andlocation of the chocolate portions deposited on the belt by thedepositor. The forming heads are decorated in a manner similar to thatset forth in Example 8. The exposed surface of the forming heads ismaintained at −20° C. The forming heads are mounted in a frame. Theframe may be rapidly and precisely driven simultaneously in both thevertical (up and down), horizontal (with and against the direction oftravel of the coated bars on the belt) and side-to-side (across thedirection of travel for fine alignment adjustment) directions throughthe application of servo motor drive mechanisms.

Starting the forming cycle, the forming heads move downward and/orhorizontally such that upon contacting the coated centers there is norelative speed between the embossing plate and the coated centers. Theforming head goes beyond contacting the top surface and continues insuch a manner to cause the sides of the chocolate portions to be formedin a manner similar to the tops. The forming head descends to a point2-3 mm above the belt. Excess deposited chocolate, if any, extrudes fromthe edges of the forming head. Excess chocolate should be used since alack of chocolate causes unwanted voids in the formed piece. The formingheads travel with and are in contact with the chocolate on the tops andsides of the coated centers for about 2 seconds after which the formingheads plate retracts and travel back to position to restart the cycle.The forming heads are of a number that is sufficient to provide thecontact time required while allowing transit time to return to thebeginning of the cycle. The formed chocolate portions are then rewarmedas set forth in Example 5 as necessary to provide optimum gloss anddetail and cooled in a cooling tunnel as also set forth in Example 5.The finished solid chocolate confection has good detail of design withacceptable gloss.

Example 12

Chocolate is prepared and tempered as set forth in Example 11. A peanutbutter containing cream is prepared and deposited onto the belt as inExample 11 simultaneously with the tempered chocolate in the manner setforth in Minifie, 3rd Ed. Pg. 204. These portions are then formed in themanner set forth in Example 11 into the shape of an truncated cone withside release angle of 20° and where the height is 12 mm and the diameteris 50 mm. The formed center filled chocolate portions are then cooled inthe manner as set forth in Example 11. The finished peanut butter filledchocolate confection has acceptable gloss and is resistant to bloomformation due to the final rapid cooling.

Example 13

Portions are deposited or co-deposited as in Example 11 or 12. For eachindividual deposit, prior to the forming head coming in contact with thedeposited portion, a chilled sleeve at a temperature of −20° C. whichcompletely surrounds the forming head first contacts the belt andencompasses the entire individual deposited portion. This effectivelytraps the deposited portion, preventing the extrusion of excess depositas set forth in Example 11. The sleeve contacts the belt 0.5 secondsprior to the first contact of the forming head and remains in positionduring the forming cycle. The motion of the sleeve is either driven, byservo motor for example, or is sprung loaded and attached to the forminghead directly and driven thereby. The finished deposited, formedconfection has no excess chocolate rim or flash as is possible in themethod set forth in Example 11.

Example 14

The rheology of tempered chocolate causes difficultly in achievingaccurate deposits. Highly accurate deposits, highly accurate beingdefined as variation of less than 0.1% by volume, of portions are made,as set forth in Example 11. The forming heads descend to the point oftouching the belt and form the deposits completely without the formationof a rims or voids.

Example 15

Deposits are made as set forth in Examples 11, 12, 13 or 14. The beltstops during the deposit and forming cycle in the manner known as“indexing”. The forming heads move up and down and the motion in thedirection of travel is stopped during the forming cycle. In this manner,the motions of the forming heads in minimized.

Example 16

Deposits are made in the manner as set forth in Example 12. The centermaterial is mixture of fats and sugars known as a white cream filling.The deposited portions are formed in the manner as set forth in Example11. The forming heads are shaped such that the formed deposited portionis in the shape of a half egg. The formed deposited portion is thencooled in a tunnel in the manner as set forth in Example 1.

Example 17

Caramel and nougat centers are formed into the shape of a half egg withthe nougat layer below the caramel layer. The overall dimensions are 50mm long, 17 mm high at the peak and 35 mm wide at the widest point. Thecenters are then enrobed in a manner similar to that set forth inExample 8 with the majority of the excess chocolate removed by shaking.Impingement blowers used on the top of enrobed centers with non-planartop surfaces such as eggs may result in thin tops. The coated centersare then embossed as set forth in Example 5. The embossed coated centersare then cooled in a tunnel as set forth in Example 4.

Example 18

Caramel/nougat centers are prepared, enrobed and embossed as set forthin Example 11. The embosser is operated at a temperature of 6° C. and acontact time of 11 seconds. This is sufficient for release. The embossedcoated centers are then cooled in a tunnel as set forth in Example 4.

The above description of the invention is intended to be illustrativeand not limiting. Various changes or modifications in the embodimentsdescribed may occur to those skilled in the art. These can be madewithout departing from the spirit or scope of the invention.

What is claimed is:
 1. A method of forming a shaped chocolate productcomprising the steps of: (a) depositing an edible mass comprising achocolate composition having a liquid fat phase onto a deposit surface;and (b) contacting at least one surface of said edible composition witha chilled forming device having a contacting surface at a temperaturebelow 10° C. thereby at least partially solidifying at least one outersurface layer of said chocolate composition in a form corresponding tosaid forming device, forming a shaped chocolate product.
 2. The methodof claim 1, wherein said chilled forming device has a contacting surfacetemperature less than 5° C.
 3. The method of claim 1, wherein saidchilled forming device has a contacting surface temperature less than 0°C.
 4. The method of claim 1, wherein said chilled forming device has acontacting surface temperature less than −5° C.
 5. The method of claim1, wherein said chilled forming device has a contacting surfacetemperature less than −10° C.
 6. The method of claim 1, wherein saidchilled forming device has a contacting surface temperature less than−15° C.
 7. The method of claim 1, wherein said chilled forming devicehas a contacting surface temperature less than −25° C.
 8. The method ofclaim 1, wherein said chocolate product is formed without the step ofdepositing the edible mass into a mold.
 9. The method of claim 1,wherein said edible mass is formed by enrobing said chocolatecomposition onto an edible center prior to said step of contacting withsaid chilled forming device.
 10. The method of claim 9, wherein saidedible mass is formed by depositing said chocolate onto an edible centerprior to said step of contacting with said chilled forming device. 11.The method of claim 9, wherein said edible center comprises an ediblecomposition selected from nougat, truffle, peanut butter, caramel,praline, nuts, marshmallow, fudge, puffed grains, cookie, biscuit,wafer, turkish delight, fondants and mixtures thereof.
 12. The method ofclaim 1, wherein said forming device sets said edible mass into athree-dimensional shape.
 13. The method of claim 1, wherein said ediblemass is deposited onto a conveyor prior to said step of contacting withsaid forming device.
 14. The method of claim 1, wherein said chocolatecomposition is co-deposited onto a conveyor belt with an ediblecomponent to form said edible mass prior to said step of contacting withsaid forming device.
 15. The method of claim 1, wherein said chocolatecomposition is deposited onto an edible substrate to form said ediblemass prior to said step of contacting with said forming device.
 16. Themethod of claim 15, wherein said edible substrate has a bottom chocolatecomposition different from said chocolate composition.
 17. The method ofclaim 1, wherein said chilled forming device is contacted with saidchocolate mass for a period time between 0.1 seconds and 2 minutes. 18.The method of claim 1, wherein said chilled forming device is contactedwith a surface of said chocolate composition for a period of timesufficient to form an outer solidified chocolate skin sufficiently thickto retain shape of said contacted surface after removal of said formingdevice.
 19. The method of claim 18, wherein solidified chocolate skin issubsequently warmed by external means to improve gloss.
 20. The methodof claim 1, wherein said shaped chocolate product is subsequently warmedby external means to improve gloss.
 21. The method of claim 1, whereinsaid deposited chocolate composition extends above said deposit surface.22. The method of claim 1, wherein said deposited chocolate compositionis bounded by a containment means.
 23. The method of claim 1, wherein anarea of contact of said deposited chocolate composition with saiddeposit surface is bounded by a containment means.
 24. The method ofclaim 21, wherein said deposit surface includes a recess volume.
 25. Themethod of claim 24, wherein said deposited chocolate composition isbounded by a containment means.
 26. The method of claim 22, wherein saidcontainment means is a recess volume on said deposit surface.
 27. Themethod of claim 26, wherein said recess volume is defined by a patternedsurface.
 28. The method of claim 22, wherein said containment means is araised ridge.
 29. The method of claim 22, wherein said containment meansis a textured surface effective to retard the spreading of saiddeposited chocolate composition.
 30. The method of claim 22, whereinsaid containment means is a temperature effective to retard thespreading of said deposited chocolate composition.
 31. The method ofclaim 22, wherein said containment means is a containment member whichcontacts said deposit surface effective to retard the spreading of saiddeposited chocolate composition.
 32. The method of claim 22, whereinsaid containment means is at least two containment members which contactsaid deposit surface effective to retard the spreading of said depositedchocolate composition.
 33. The method of claim 32, wherein saidcontainment members include topological features effective to formcorresponding portions on said shaped chocolate product.
 34. The methodof claim 33, wherein said topological features are undercutting featureseffective to form corresponding overhang portions on said shapedchocolate product.
 35. The method of claim 1, further including a stepof engaging a containment member with said deposit surface to retard thespreading of said deposited chocolate composition.
 36. The method ofclaim 35, wherein said step of engaging occurs prior to step (a) ofdepositing.
 37. The method of claim 35, wherein said step of engagingoccurs subsequent to step (a) of depositing.
 38. The method of claim 1,wherein said deposit surface is of low surface energy.
 39. The method ofclaim 1, wherein said contacting surface is of a surface energyeffective to promote release.
 40. The method of claim 1 or 35, whereinsaid deposited chocolate composition is bounded by a flow impedingmeans.
 41. The method of claim 40, wherein said flow impeding means is arecess volume on said deposit surface.
 42. The method of claim 41,wherein said recess volume is defined by a patterned surface.
 43. Themethod of claim 40, wherein said flow impeding means is a raised ridge.44. The method of claim 40, wherein said flow impeding means is atextured surface effective to retard the spreading of said depositedchocolate composition.
 45. The method of claim 40, wherein said flowimpeding means is a temperature effective to retard the spreading ofsaid deposited chocolate composition.
 46. The method of claim 40,wherein said flow impeding means is a flow impeding member whichcontacts the surface effective to retard the spreading of said depositedchocolate composition.